Reinforced Polymer Sprocket and Bushing for High-Torque Drives
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Solution Overview
Problem
Conventional sprockets and bushings used in high torque applications are often made of metal, leading to durability issues, wear, and increased mass, which complicates handling, installation, and drive inertia.
Innovation Solution
Development of non-metal high torque sprockets and bushings formed from castable polymer materials with embedded textile reinforcements, such as nylon or carbon cordage, which are designed to engage conventional bushings and provide a lightweight, durable solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal sprockets and bushings are used for high torque applications, then strength and durability are improved, but mass increases leading to higher drive inertia and energy requirements
Solution Approach 1:
The patent applies composite materials by combining polymer matrix with embedded textile reinforcement (such as aramid, nylon, or carbon fiber) to create a non-metal sprocket that achieves high strength-to-weight ratio. The textile reinforcement provides tensile strength while the polymer matrix binds the fibers together, creating a composite structure that is both strong and lightweight, resolving the contradiction between strength and mass.
Solution Approach 2:
The patent changes the material parameters by transitioning from metal to polymer-composite materials, fundamentally altering the density and strength characteristics. This parameter change enables the sprocket to maintain sufficient strength for high torque applications while reducing mass significantly, thereby lowering drive inertia and energy requirements.
2Strength
If metal bushings are used to secure non-metal sprockets, then connection strength is improved, but mass and handling difficulty increase
Solution Approach 1:
The patent applies homogeneity by making both the sprocket and bushing from the same non-metal polymer material, creating a homogeneous material system. This eliminates the mass penalty of metal bushings while maintaining adequate connection strength through the polymer-polymer interface, improving handling ease without sacrificing connection capability.
3Ease of manufacture
If conventional non-metal pulleys with straight bore and set screw are used, then manufacturing simplicity is improved, but durability and torque capacity are insufficient
Solution Approach 1:
The patent applies composite materials by embedding textile reinforcement within the polymer matrix of the sprocket body. This composite structure significantly enhances durability and torque capacity compared to unreinforced plastic pulleys, while the casting process maintains manufacturing simplicity. The reinforcement fibers distribute stress more effectively, preventing failure under high torque loads.
Solution Approach 2:
The patent changes the material parameters by incorporating reinforcement fibers into the polymer matrix, fundamentally altering the mechanical properties. This parameter change transforms the material from simple plastic to reinforced composite, enabling it to withstand high torque applications while maintaining the ease of casting manufacturing process.
4Power
If metal sprockets are used for high torque applications, then torque capacity is improved, but wear and erosion cause failure over time
Solution Approach 1:
The patent applies composite materials by using polymer matrix combined with textile reinforcement to create a non-metal sprocket capable of withstanding high torque. The composite structure provides both the necessary torque capacity and improved wear resistance, as the polymer material does not suffer from the same erosion and wear issues that plague metal sprockets in high torque applications.
Data Source
AI summary
An apparatus includes a non-metal high torque sprocket and non-metal bushing. The non-metal high torque sprocket includes a body defining an outer periphery and a hub section defining an inner surface for engaging a bushing, a continuous toothed structure disposed on the outer periphery of the body, and a textile reinforcement embedded in the body adjacent the inner surface of the hub section, wherein the body is formed of a castable polymer material. The hub section inner surface is a tapered shape, and is adapted to engage a conventional QD bushing or a taper-lock bushing. The non-metal bushing is engageable by the hub section inner surface of the high torque sprocket. The non-metal bushing may be formed of a castable polymer material, which may optionally include ultra-high molecular weight powder. According to some embodiments, the non-metal bushing is a QD bushing.